Method for accelerated aging of catalytic converters incorporating injection of volatilized lubricant

ABSTRACT

A method and apparatus for accelerated aging of an automotive catalytic converter under conditions incorporating volatilized oil consumption.

PRIORITY DATA

[0001] The present application is a continuation-in-part of U.S. patent application Ser. No. 10/213,890, incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present application relates in general to an apparatus, and to a method of using an apparatus to simulate the consumption of the volatile components of oil by an engine. The apparatus can be engine based, but preferably is an non-engine based exhaust component rapid aging system (NEBECRAS).

BACKGROUND

[0003] An automotive catalytic converter is an emissions control device that may be incorporated into the exhaust system of a motor vehicle between the exhaust manifold and the muffler. The catalytic converter contains one or more catalysts, such as those based on platinum, palladium, or rhodium, that reduce the levels of hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxides (NOx) in the exhaust gas, thereby reducing the amount of these pollutants which would otherwise be emitted into the atmosphere from the vehicle. In a typical commercial catalytic converter, HC and CO in the exhaust are oxidized to form carbon dioxide (CO2) and water, and NOx are reduced to nitrogen (N2).

[0004] As a result of recent regulatory initiatives, motor vehicle emissions control devices, including catalytic converters, are now required to have longer useful lives. US regulatory authorities such as the US Environmental Protection Agency (EPA) and the California Air Resources Board (CARB) now require automotive emission control elements to function up to 150,000 vehicle miles. This requirement, coupled with tighter emission standards, places severe demands on catalytic converters and other exhaust emissions control devices. Catalytic converters lose efficiency primarily by two mechanisms. High exhaust temperatures can cause thermal damage, and a number of components introduced into the typical automotive internal combustion engine exhaust, e.g. from the lubricating oil, can act as poisons to the catalyst present in the converter.

[0005] In order to accommodate these stringent EPA requirements, it is important to develop methods for accelerated aging that adequately simulate the impact of various engine operating modes, and various oil components. A method is needed to simulate the consumption of the volatile components of oil in order to adequately and efficiently assess the impact of such consumption on the aging of a catalytic converter.

SUMMARY OF THE INVENTION

[0006] A non-engine based exhaust component rapid aging system (NEBECRAS) comprising a combustor in fluid communication with an air supplier, a fuel supplier, a volatilized oil supplier, and a catalytic converter, said combustor being adapted to provide substantially continuous and effective stoichiometric combustion of a feedstream to produce an exhaust product.

BRIEF DESCRIPTION OF THE FIGURES

[0007]FIG. 1 shows a schematic diagram of one embodiment of the FOCAS® system.

[0008]FIG. 2 is a schematic of the existing bulk oil injection subsystem in the FOCAS® rig.

[0009]FIG. 3 is a schematic of the proposed volatilization subsystem integrated into the FOCAS® rig.

[0010]FIG. 4 is a schematic of the volatile reservoir for volatile oil injection.

[0011]FIG. 5 depicts a linear calculation of phosphorus depletion with the given V-C factor.

BRIEF DESCRIPTION

[0012] The present application provides an apparatus and a method for simulating the impact of volatile oil components on a catalytic converter. The apparatus can be an engine based apparatus or a non-engine based apparatus. In a preferred embodiment, the apparatus is a non-engine based exhaust component rapid aging system (NEBECRAS), most preferably a FOCAS® rig.

[0013] As used herein, the term “catalytic converter” means a full scale emissions control device suitable for incorporation into the exhaust system of a motor vehicle between the exhaust manifold and the muffler. “Extended driving conditions” refers to the equivalent of at least about 50,000 vehicle miles, preferably up to 100,000 vehicle miles, more preferably up to 150,000 vehicle miles.

[0014] A preferred NEBRECRAS for use in the method is the “FOCAS® rig,” described in U.S. Patent Application Publication No. 20030079520, published May 1, 2003, incorporated herein by reference. Briefly, the FOCAS® rig comprises: (1) an air supply system to provide air for combustion to the burner, (2) a fuel system to provide fuel to the burner, (3) a burner system to combust the air and fuel mixture and to provide the proper exhaust gas constituents, (4) a heat exchanger to control the exhaust gas temperature, (5) an oil injection system, and (6) a computerized control system. The foregoing components are described in detail in U.S. Patent Application Publication No. 20030079520, published May 1, 2003, which has been incorporated herein by reference, and will not be described in detail herein.

[0015] The FOCAS® rig was developed to evaluate the long term effects of the individual variables on the long term performance of the catalyst. The FOCAS® rig is capable of producing a simulated exhaust gas with a composition and temperature corresponding to that produced by the internal combustion engine of a motor vehicle. The burner system in the FOCAS® rig comprises a nozzle comprising a swirl plate which is effective even at a stoichiometric air to fuel ratio (AFR) of producing a feedstream flowpath comprising an air shroud effective to prevent flame from attaching to the nozzle during combustion of the fuel. The swirl plate is effective to substantially continuously and effectively stoichiometrically combust the feedstream while preventing the flame from remaining in constant contact with an inner wall of the combuster tube.

[0016] In the present application, a volatilization subsystem is integrated into the oil injection system of the NEBECRAS, preferably into a FOCAS® rig, to simulate the consumption of the volatile components of oil, and the system thereafter evaluates the impact of the consumption of these volatile components of oil on the aging of the catalytic converter.

[0017] Although the FOCAS® rig is preferred, it will be apparent to persons of ordinary skill in the art that any functional and effective NEBECRAS could be adapted for use in accordance with the principles described herein, and that an engine based rig also could be altered to incorporate the volatilization sub-system described herein.

[0018] The Oil Injection System

[0019] In a preferred embodiment, the method and apparatus take advantage of the oil injection system which is part of the FOCAS® rig. The current oil injection system (12 in FIGS. 1 and 2) uses pressurized nitrogen to atomize the bulk oil consumption for injection through the oil injection nozzle 14. In the present application, the pressurized nitrogen system, including the oil injection nozzle 14, is used to add volatilized fractions of P from the oil.

[0020] A schematic of the proposed volatilization sub-system 16 integrated into the current system is shown in FIG. 3. The sub-system includes a volatile reservoir 18 preferably comprising a temperature control unit 20. Exhaust gas is pulled from the FOCAS® rig, preferably at a point downstream from the heat exchanger and upstream from the oil injector 12. Exhaust gas is carried through first tubing 19 to an eductor 15. Nitrogen is carried through second tubing 23 preferably via a pressure regulator 21 to the eductor 15. The combined exhaust gas and nitrogen are bubbled through the oil in the reservoir 18 via a gas injection probe 25, shown in more detail in FIG. 4.

[0021] Referring to FIG. 4, a preferred gas injection probe is ⅛ inch stainless steel tubing comprising an inlet probe 29 which branches to form three probe arms: a first probe arm 27 a, a second probe arm 27 b, and a third probe arm 27 c, respectively. The probe arms 27 a-c preferably are welded shut at first, second, and third terminal ends 28 a, 28 b, and 28 c, respectively.

[0022] The tubing defines openings 30 through which the combined nitrogen/exhaust gas stream is released into the oil. The openings 30 preferably are random, and the inlet probe 29 preferably comprises fewer openings 30 than any of the probe arms 27 a-c. In a most preferred embodiment, the inlet probe has about ¼ the number of openings 30 as the number of openings 30 in the probe arms 27 a-c. A pressure regulator 21 preferably maintains the nitrogen at a pressure of from about 5 to about 40 psi in order to ensure sufficient volatilization of the oil and sufficient atomization in the bulk injector.

[0023] The reservoir preferably comprises a sealable opening, such as a threaded seal cap, preferably about a 1½ inch fill cap which is maintained closed during use. The combination of nitrogen and volatilized oil flows through the volatilized oil injection tubing 24 to the oil injection nozzle 14. In a preferred embodiment, the oil injection tubing 24 is engaged with an outlet 32 comprising an outlet tap 34 protected on the reservoir side by a cover 36.

[0024] As seen in FIG. 4, the cover 36 comprises a splash shield 38. The splash shield 38 projects inward from the surface of the reservoir for a distance effective to allow N₂ and volatilized components to be pushed out while preventing bulk oil consumption from the reservoir. Preferably, the splash shield projects inward about ½ inch.

[0025] In order to maintain a correct balance of bulk-P consumption to volatile-P consumption, the volatile-consumption (V-C) factor for the OPEST II test approach, and the real phosphorus depletion curve are determined. In order to determine these values, the system is run for a period of time and the phosphorus content of the oil is analyzed. Because removing samples from the plenum will modify the overall volume of oil, which also should modify the volatile-phosphorus (P) consumption rate, several tests are run for a varying number of hours. A fresh oil charge is made at the beginning of each test. Preferably, tests are run to the following number of hours: 1, 2, 3, 4, 6, 8, 10, 15, and 20. For each test point, the phosphorus content of the oil is measured. The data provides information on volatile consumption and phosphorus depletion, and provides the data to determine the real V-C factor and the P-depletion curve. Using this information, the procedure can be adjusted, and an oil change schedule can be created.

[0026] Creating the Oil Change Schedule

[0027] Assuming that about 60 percent of the phosphorus (P)-consumption in an engine under normal operating conditions is volatile P-consumption, the mass of volatile-P that should be consumed during a 200 hour OPESTII aging procedure (on 0.011P oil) will be related to the mass of P consumed by bulk consumption. The mass of P consumed by bulk oil consumption during a 200-hour aging procedure where 6 quarts of oil are consumed is:

6 Qts. Oil×820 g/Qt.×0.0011=5.4 g Bulk-P

[0028] Based on this bulk consumption, the volatile consumption could be: ${P_{Bulk} \times 5.4 \times \left( \frac{0.6}{0.4} \right)} + {8.1\quad g\quad {Volatile}} - P$

[0029] During the OPEST II test, the FOCAS® rig consumes 30 grams of bulk oil per hour. This produces a Bulk-P consumption rate of: ${30\frac{g}{hr} \times 0.0011 \times 1000\frac{mg}{g}} = {{33\frac{mg}{hr}\quad {Bulk}} - P}$

[0030] If we would like 60 percent of the total P-consumption to be Volatile-P, then based on the FOCAS® bulk oil consumption, we need: ${33\frac{mg}{hr} \times \left( \frac{0.6}{0.4} \right)} = {{49.5\frac{mg}{hr}\quad {Volatile}} - P}$

[0031] Based on the published Selby-Noak test, the volatiles-collecting bench procedure runs the following conditions:

[0032] 250° F. (to simulate the upper ring-belt temperature)

[0033] 60 minutes

[0034] 65 g oil

[0035] a slight vacuum (to induce air flow across sample)

[0036] Selby, T., “Development and Significance of the Phosphorus Emission Index of Engine Oils,” 13th International Colloquium Tribology—Lubricants, Materials, and Lubrication Technische Akademie Esslingen, Stuttgart/Ostfildern, Germany. Jan. 15-17, 2002, incorporated herein by reference.

[0037] The Selby-Noak test produces a range of mass of volatile-Phosphorus emission, but the average is about 2 mg. If we assume the value of 2 mg/hour to be a reasonable emission rate for that mass of oil, at the given temperature in one hour, then we can calculate the conditions we need for the OPEST II test.

[0038] The Selby-Noak test uses 65 grams of oil and produces about 2 mg of volatile P in one hour. This gives us a scaling factor, let's call it the volatile consumption factor (V-C factor) of: $\frac{{2\quad {mg}\quad {Volatile}} - P}{{65\quad g\quad {Oil}} - {hr}}$

[0039] If we assume volatility is linear (i.e., more oil produces more volatile P, in proportion to the V-C factor), then the volatilization container would need to hold about 2 quarts of oil. The real V-C factor will set the volume of the volatile reservoir. ${49.5\frac{mg}{hr} \times \frac{65\quad g}{2\quad {mg}} \times \frac{1\quad {{Qt}.}}{820\quad g}} = {1.96\quad {{Qts}.}}$

[0040] At this Volatile-P rate, assuming that the P-depletion is linear (which it probably is not), the Phosphorus from a two quart sample would be depleted in about 40 hours. See FIG. 5 for a linear calculation of the depletion. This relation will set the change interval for the oil in the volatile reservoir.

[0041] Persons of ordinary skill in the art will recognize that many modifications may be made to the present application without departing from the spirit and scope of the application. The embodiment described herein is meant to be illustrative only and should not be taken as limiting the application, which is defined in the claims. 

We claim:
 1. A non-engine based exhaust component rapid aging system (NEBECRAS) comprising a combustor in fluid communication with an air supplier, a fuel supplier, a lubricant supplier comprising a volatilized lubricant supplier, and a catalytic converter, said combustor being adapted to provide substantially continuous and effective stoichiometric combustion of a feedstream to produce an exhaust product.
 2. The NEBECRAS of claim 1 wherein the lubricant supplier comprises an oil injection nozzle in fluid communication with said volatilized lubricant supplier.
 3. The NEBECRAS of claim 2 wherein said volatilized lubricant supplier comprises a reservoir adapted to hold a volume of lubricant effective to simulate consumption of volatilized oil by an engine.
 4. The NEBECRAS of claim 3 wherein said reservoir is in fluid communication with a source of pressurized gas.
 5. The NEBECRAS of claim 3 wherein said reservoir is in fluid communication with said combustor, thereby providing a source of said exhaust product.
 6. The NEBECRAS of claim 5 wherein said fluid communication comprises a probe effective to deliver a combination of said pressurized gas and said exhaust product through said volume of lubricant.
 7. The NEBECRAS of claim 6 wherein said reservoir comprises a temperature control unit effective together with said combination of said pressurized gas and said exhaust product to volatilize an amount of said lubricant.
 8. The NEBECRAS of claim 7 wherein said probe comprises tubing comprising openings therethrough.
 9. The NEBECRAS of claim 8 wherein said probe comprises an inlet probe in fluid communication with a first probe arm, a second probe arm, and a third probe arm.
 10. The NEBECRAS of claim 9 wherein said inlet probe comprises a number of openings and said first, second, and third probe arms comprise one or more independent quantit(ies) of openings.
 11. The NEBECRAS of claim 10 wherein said number of openings is about {fraction (1/4)} as many as said one or more independent quantit(ies) of openings.
 12. The NEBECRAS of claim 11 wherein said fluid communication between said reservoir and said oil injection nozzle comprises volatilized oil injection tubing.
 13. The NEBECRAS of claim 7 wherein said reservoir comprises an exit port engaged with said volatilized oil injection tubing, said exit port being adapted to prevent droplets of bulk oil from entering said volatilized oil injection tubing.
 14. The NEBECRAS of claim 13 wherein said exit port comprises an external side and a reservoir side, said reservoir side comprising a cover effective to permit gas and volatilized oil to pass to said volatilized oil injection tubing and to prevent droplets of bulk oil from passing to said volatilized oil injection tubing.
 15. The NEBECRAS of claim 3 wherein said volume of lubricant is about 2 quarts.
 16. The NEBECRAS of claim 5 wherein said volume of lubricant is about 2 quarts.
 17. The NEBECRAS of claim 6 wherein said volume of lubricant is about 2 quarts.
 18. The NEBECRAS of claim 14 wherein said volume of lubricant is about 2 quarts.
 19. A NEBECRAS for aging a catalytic converter comprising: catalytic converter means; combustion means in fluid communication with said catalytic converter means, said combustion means being effective to provide substantially continuous stoichiometric combustion of automotive fuel; fuel injection means in fluid communication with said combustion means; and, lubricant injection means comprising means for injecting volatilized lubricant in fluid communication with said catalytic converter means.
 20. A NEBECRAS for aging a catalytic converter comprising: a burner adapted to provide substantially continuous and effective stoichiometric combustion of a feedstream to produce an exhaust product; a fuel injector system in fluid communication with said burner; a lubricant injector system in fluid communication with said burner, said lubricant injector system being adapted to inject volatilized lubricant; and, a catalytic converter in fluid communication with said exhaust product.
 21. The NEBECRAS of claim 20 wherein the lubricant injector system comprises a lubricant reservoir retaining a volume of lubricant, the lubricant reservoir being in fluid communication with a source of gas and in fluid communication with an oil injection nozzle.
 22. The NEBECRAS of claim 21 wherein said lubricant reservoir is in fluid communication with said combustor, thereby providing a source of said exhaust product.
 23. The NEBECRAS of claim 22 wherein said fluid communication comprises a probe effective to deliver a combination of said pressurized gas and said exhaust product through said volume of lubricant.
 24. The NEBECRAS of claim 23 wherein said reservoir comprises a temperature control unit effective together with said combination of said pressurized gas and said exhaust product to volatilize an amount of said lubricant.
 25. The NEBECRAS of claim 24 wherein said probe comprises tubing comprising openings therethrough.
 26. The NEBECRAS of claim 25 wherein said probe comprises an inlet probe in fluid communication with a first probe arm, a second probe arm, and a third probe arm.
 27. The NEBECRAS of claim 26 wherein said inlet probe comprises a number of openings and said first, second, and third probe arms comprise one or more independent quantit(ies) of openings.
 28. The NEBECRAS of claim 27 wherein said number of openings is about {fraction (1/4)} as many as said one or more independent quantit(ies) of openings.
 29. The NEBECRAS of claim 28 wherein said fluid communication between said reservoir and said oil injection nozzle comprises volatilized oil injection tubing.
 30. The NEBECRAS of claim 29 wherein said reservoir comprises an exit port engaged with said volatilized oil injection tubing, said exit port being adapted to prevent droplets of bulk oil from entering said volatilized oil injection tubing.
 31. The NEBECRAS of claim 30 wherein said exit port comprises an external side and a reservoir side, and the reservoir side comprises a cover effective to permit gas and volatilized oil to pass through the cover but to prevent droplets of bulk oil from passing through the cover.
 32. The NEBECRAS of claim 20 wherein said volume of lubricant is about 2 quarts.
 33. The NEBECRAS of claim 24 wherein said volume of lubricant is about 2 quarts.
 34. The NEBECRAS of claim 30 wherein said volume of lubricant is about 2 quarts.
 35. The NEBECRAS of claim 31 wherein said volume of lubricant is about 2 quarts.
 36. A process for simulating the impact of volatile oil consumption on a catalytic converter, the method comprising: providing a non-engine based exhaust component rapid aging system (NEBECRAS) comprising a combustor in fluid communication with an air supplier, a fuel supplier, an oil injection nozzle in fluid communication with a source of volatilized oil, and a catalytic converter, said combustor being adapted to provide substantially continuous and effective stoichiometric combustion of a fuel feedstream to produce an exhaust product; exposing said catalytic converter to accelerated aging conditions comprising a flow of volatilized lubricating oil from a reservoir at an initial flow rate for an initial flow time effective to simulate the flow of volatilized lubricating oil to the catalytic converter during operation of an engine, producing a volatilized lubricant aged catalytic converter.
 37. The process of claim 36 further comprising analyzing the phosphorus content of the lubricant remaining in the reservoir.
 38. The process of claim 37 comprising providing a fresh charge of lubricant to said reservoir; and, exposing said catalytic converter to second accelerated aging conditions comprising a flow of volatilized lubricating oil from the reservoir at a second flow rate for a second flow time effective to simulate the flow of volatilized lubricating oil to the catalytic converter during operation of an engine, producing a volatilized lubricant aged catalytic converter; and, analyzing the phosphorus content of the lubricant remaining in the reservoir.
 39. The process of claim 38 further comprising providing additional fresh charges of lubricant and thereafter exposing said catalytic converter to the accelerated aging conditions for a plurality of lengths of time.
 40. The process of claim 39 wherein said plurality of lengths of time are the following number of hours: 1, 2, 3, 4, 6, 8, 10, 15, and
 20. 41. The process of claim 38 further comprising determining the real volatile consumption (V-C) factor and phosphorus (P)-depletion curve for the process and using said real V-C factor and P-depletion curve to determine an effective volume of oil and oil change interval for said process.
 42. The process of claim 39 further comprising determining the real V-C factor and P-depletion curve for the process and using said real V-C factor and P-depletion curve to determine an effective volume of oil and oil change interval for said process.
 43. The process of claim 38 further comprising evaluating the efficiency of the volatilized lubricant aged catalytic converter.
 44. The method of claim 43 further comprising preventing contamination of said flow of volatilized lubricating oil by droplets of oil from said reservoir.
 45. A process for simulating catalytic converter aging using a non-engine based exhaust component rapid aging system (NEBECRAS), the method comprising: supplying fuel and volatilized lubricant to a combustor via a nozzle at an air to fuel ratio (AFR) and under conditions effective to produce a feedstream flowpath comprising an air shroud effective to prevent flame from attaching to the nozzle during combustion of the fuel; substantially continuously and effectively stoichiometrically combusting the feedstream while preventing the flame from remaining in constant contact with an inner wall of the combuster tube, thereby producing an exhaust product; and exposing a catalytic converter to the exhaust product, producing a volatilized lubricant aged catalytic converter.
 46. The process of claim 45 further comprising analyzing the phosphorus content of the lubricant remaining in the reservoir.
 47. The process of claim 46 comprising providing a fresh charge of lubricant to said reservoir; and, exposing said catalytic converter to second accelerated aging conditions comprising a flow of volatilized lubricating oil from the reservoir at a second flow rate for a second flow time effective to simulate the flow of volatilized lubricating oil to the catalytic converter during operation of an engine, producing a volatilized lubricant aged catalytic converter; and, analyzing the phosphorus content of the lubricant remaining in the reservoir.
 48. The process of claim 47 further comprising providing additional fresh charges of lubricant and thereafter exposing said catalytic converter to the accelerated aging conditions for a plurality of lengths of time.
 49. The process of claim 48 wherein said plurality of lengths of time are the following number of hours: 1, 2, 3, 4, 6, 8, 10, 15, and
 20. 50. The process of claim 47 further comprising determining the real V-C factor and P-depletion curve for the process and using said real V-C factor and P-depletion curve to determine an effective volume of oil and oil change interval for said process.
 51. The process of claim 48 further comprising determining the real V-C factor and P-depletion curve for the process and using said real V-C factor and P-depletion curve to determine an effective volume of oil and oil change interval for said process.
 52. The process of claim 49 further comprising evaluating the efficiency of the volatilized lubricant aged catalytic converter.
 53. The method of claim 52 further comprising preventing contamination of said flow of volatilized lubricating oil by droplets of oil from said reservoir.
 54. A method for simulating catalytic converter aging using a NEBECRAS, the method comprising: supplying fuel to a combustor tube via a nozzle at an AFR under conditions effective to produce a feedstream flowpath comprising an air shroud effective to prevent flame from attaching to the nozzle during combustion of the fuel; injecting volatilized lubricant into said feedstream flowpath; substantially continuously and effectively stoichiometrically combusting components of the feedstream selected from the group consisting of the fuel, the lubricant, and combinations thereof to produce an exhaust product; and exposing a catalytic converter to the exhaust product, producing an aged catalytic converter.
 55. The process of claim 54 further comprising analyzing the phosphorus content of the lubricant remaining in the reservoir.
 56. The process of claim 55 further comprising providing additional fresh charges of lubricant and thereafter exposing said catalytic converter to the accelerated aging conditions for a plurality of lengths of time.
 57. The process of claim 56 wherein said plurality of lengths of time are the following number of hours: 1, 2, 3, 4, 6, 8, 10, 15, and
 20. 58. The process of claim 54 further comprising determining the real V-C factor and P-depletion curve for the process and using said real V-C factor and P-depletion curve to determine an effective volume of oil and oil change interval for said process.
 59. The process of claim 56 further comprising determining the real V-C factor and P-depletion curve for the process and using said real V-C factor and P-depletion curve to determine an effective volume of oil and oil change interval for said process.
 60. The process of claim 58 further comprising evaluating the efficiency of the volatilized lubricant aged catalytic converter.
 61. The method of claim 60 further comprising preventing contamination of said flow of volatilized lubricating oil by droplets of oil from said reservoir. 